You can use metal
hinges on the box, but I
prefer to make my own
out of the woods I’m
using. You can use scrap
wood to make them,
and it’s just a few more
cuts with the scroll saw.
But it’s worth it to have
perfectly matching
hinges for your box!

Rough out the hinges. Start by making two
photocopies of the right view hinge pattern.
Attach the patterns to the hinge blank using
the glue stick. Cut out this profile on the
scroll saw. Attach the other pattern to the
opposite side (so you know where to drill, see Step 2).

Step 2: Drill an 1/8"-diameter hole half way through
the hinge blank where marked on the
pattern. The dimple from the center punch
will help to line the drill bit up properly.
Support the hinge with a block of wood.
Then turn the blank over and drill another
hole where the diagonals connect. Drill deep
enough to meet the hole drilled in the other
side. Follow the same procedure to drill the
hinge-pin hole on the opposite end.

Step 3: Cut out the hinge barrels. Attach the top
view pattern to the hinges and cut along the
solid lines. Do not separate the hinge halves until Step6.

Step 4: Round over Side A of the hinge using a
detail sander or belt sander. Then round off
one corner of Side B—leave the other corner
square. The square corner will act as a
natural stop and prevent the hinge from
opening more than 100° to 110°.

Step 5: Mark one of the two hinge barrels on Side A
with an “x.” Use a 9/64"-diameter bit to
enlarge the hinge-pin hole on that side a
little bit. Do not enlarge hinge-pin hole in the
other hinge barrel on Side A. Then reverse
the hinge and use the 9/64"-diameter drill bit
to enlarge the hinge-pin hole in Side B.

Step 6: Cut the hinge in half following the lines on
the pattern.

Step 7: Dry assemble the hinges, following the
hinge assembly diagram, using a nail that
fits loosely through the holes. You want to
make sure that the hinge opens the proper
amount and doesn’t catch or bind at any
point.

Step 8: Mark any places where the hinges bind.
Sand those areas until the hinge opens
freely.

Step 9: Assemble the hinges using an 1/8"-diameter
dowel. Glue the dowel in place using wood
glue. Trim off any overhanging dowel with
the scroll saw and sand the area smooth.

About the Author
Gary has been scrolling
since 1992 and has been
making jewelry boxes on
the band saw and table
saw since 1986. Designing
and making jewelry boxes
on his DeWalt 788 saw are
his primary interests. This
is Gary’s second article in
Scroll Saw Workshop. His first article was
“Octagonal Jewelry Boxes”, featured in Summer
2004 (Issue #15). Gary’s other interests are golf, gardening, and attending craft
shows.

This project is courtesy of Scroll
Saw Woodworking & Crafts Magazine.
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